Instructions for Installation and Operation

DC Motor Speed Control

Model 1865, for 115/230 VAC power supply,
with NEMA 4 enclosure and line filter for CE

Specifications
Product Type:................................................................................... UPM-3318E4
Input Voltage: .................................................................................. 115 or 230 VAC +/- 10%,
Single Phase, 50/60Hz
Output Voltage: ............................................................................... Adjustable, 0 to 90 or
0 to 180 VDC

www.bodine-electric.com

07401043.D
QUICK REFERENCE
This manual contains the basic information needed to install and operate
Bodine DC Motor Speed Control model 1865. This manual does not profess to
cover all details or variations in equipment, nor to provide for every possible
contingency associated with installation, operation, or maintenance. No
warranty of fitness for purpose is expressed or implied. Should further
information be desired or should particular problems arise which are not
covered sufficiently for the user’s purpose, the matter should be referred to
the Bodine Electric Company.

IMPORTANT
Read this manual completely and carefully. Pay special attention to all
warnings, cautions, and safety rules. Failure to follow the instructions
could produce safety hazards that could injure personnel or damage the
control, motor, or other equipment. If you have any doubts about how to
connect the control or motor, refer to the detailed sections of this manual.

DIP

Figure 1 – Overview of installation for reference only and not be used

as a replacement for the detailed instructions within this manual.

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TABLE OF CONTENTS
QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PRODUCT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
IMPORTANT SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Step 1 – Examine Before Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Step 2 – Choose a Suitable Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Step 3 – Mount the Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Step 4 – Preliminary Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Step 5 – Connect Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Step 6 – Connect AC Line Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Step 7 – Close and Seal Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Step 8 – Connect to AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Step 9 – Check System Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Step 10 – Operate the Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Step 11 – Adjust Trim Pots (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

© 2019 Bodine Electric Company.

All rights Reserved. All data subject to change without notice. Printed in U.S.A.

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PRODUCT SPECIFICATIONS
ABOUT THIS PRODUCT—Bodine’s Model 1865 is designed to provide
variable speed control of standard Permanent Magnet DC motors. Adjustable
acceleration and deceleration are provided, making the drive suitable for soft
start applications. The full-featured drive is easy to install and operate. Simple
trim pot adjustments eliminate the computer-like programming required on
other drives. However, for most applications, no adjustments are necessary.

Table 1 – Electrical Ratings

Parameter Specification
Input Volts 115 or 230 VAC +/- 10%, Single Phase, 50/60Hz
Max. Continuous Input Current 3.4 Amps RMS
Output Volts 0 to 90 VDC or 0 to 180 VDC
Max. Continuous Output Current 2.1 Amps DC
Max. Peak Output Current 5.1 Amps DC
Max. Form Factor 1.6
1/5 HP @ 90V
Maximum Motor HP
1/3 HP @ 180V

Table 2 - General Performance Specifications

Parameter
Speed Signal Input Voltage
Minimum Speed Trim Pot
Range
Maximum Speed Trim Pot
Range
Acceleration Trim Pot Range
Deceleration Trim Pot Range
Peak Current Limit Trim Pot
Range
Speed Regulation (Change in
motor speedfrom no load to
full load)
Operating Temperature
Range
Specification Factory Setting
0 – 5 VDC (must be isolated from
N/A (speed pot)
AC line)
0 – 50 VDC output to motor with
0 VDC (full CCW)
input speed signal set at 0 VDC
60 – 100% of full motor speed with
100%
input speed signal set at 5 VDC
.2 – 10 seconds to ramp output
voltage up from 0 to 90 VDC and 2 sec. (0-90V) 4 sec.
.2 – 20 seconds to ramp up from 0 (0-180V)
to 180 VDC
.2 – 10 seconds to ramp output
voltage down from 90 to 0 VDC 2 sec. (90-0V) 4 sec.
and .2 – 20 seconds to ramp down (180-0V)
from 180 to 0 VDC
0 to 200 – 250% of motor name-
plate rating with appropriate DIP 200 – 250% (full CW)
switch settings
Less than 2% of Rated Speed with
most motors and less than 1% 1 – 2%
with many
0 to +40OC N/A

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IMPORTANT SAFETY PRECAUTIONS
Model 1865 has been evaluated by Underwriters Laboratories for conformance
to UL standards 508 and 50 and CSA standard C22.2 No. 14 and bears the UL
Recognized Component mark.

The DC control is a power electronic device. For safety reasons, please read
through this operations manual in detail and observe those paragraphs with
the safety alert symbol.

This is the safety alert symbol. It is used to alert you to potential

! personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.

WARNING indicates a potentially hazardous

! WARNING situation which, if not avoided, could result in
death or serious injury.

CAUTION indicates a potentially hazardous

! CAUTION situation which, if not avoided, may result in
minor or moderate injury.

CAUTION used without the safety alert symbol

CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in property
damage.

! WARNING
• Do not touch printed circuit board (PCB) right after turning off power.
Wait until green LED on turns off.
• Do not attempt to wire circuitry while power is on.
• Do not attempt to examine components and signals on the PCB while the
inverter is operating.
• Do not attempt to disassemble or modify internal circuitry, wiring, or
components of the inverter.
• Enclosure must be properly grounded.

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INSTALLATION
This control should only be installed by a qualified person familiar with its
operation and associated hazards. The National Electrical Code (NEC),
local electrical and safety codes, and when applicable, the Occupational
Safety and Health Act (OSHA) should be observed to reduce hazards to
personnel and property.

NOTE: The control does not provide motor overload or over temperature
protection. The user is responsible for providing this protection in the
equipment where this control is used (Remarque: La détection de la surchauffe
du moteur n’est pas assurée par cette control).

Step 1. Examine before installation

Check that the model number on the control matches the model number
ordered. The control model number is printed as part of the serial number on an
adhesive label on the outside bottom surface of the control enclosure. Carefully
examine the control for shipping damage. Parts errors should be reported to
Bodine. Shipping damage claims should be made to the freight carrier.

RoHS
COMPLIANT

Figure 2 – Location of the model number on the nameplate.

! CAUTION
Do not connect the control to the power supply if there is any sign of
damage. Notify the carrier and your distributor immediately.

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Step 2. Choose a Suitable Location
The installation site directly impacts the functionality and lifespan of the
control.
• Avoid areas where surrounding air temperature exceeds 40°C (direct
sunlight or near heating equipment or inside a panel without a cooling fan.
• Avoid locations where the front panel dial and switch may be bumped and
accidentally turned on/off or damaged.
• Avoid environments with corrosive gas.
• Avoid locations near radioactive matter or flammable material.
• Avoid locations near equipment that generate electromagnetic interference
(soldering or power machinery).
• Avoid mounting the control to a surface that vibrates.

6.16 REF.

Step 3 – Mount the Control 4.55 REF.

Prepare the mounting surface by

drilling four holes with their centers
located as shown in Figure 3. If #10 TYPE UPM
ADJUSTABLE SPEED

screws are to be used for mounting, TORQUE CONTROL

then use a #6 (.204) clearance drill.

SPEED•DREHZAHL•VITESSE
50 60
40
30 70

If #10- 32 machine screws are to be 20 80

used for mounting, then use a #20 10

0 100
90

(.161) tap drill. After the mounting

8.44 REF.

surface has been prepared,

9.14

mount the control with screws

through the four mounting brackets
(already attached to back of control
enclosure). ON•EIN•MARCHE

OFF• AUS• ARRET

3.94 REF.

Figure 3 – Mounting Dimensions

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CONNECTION
CAUTION
• The PCB inside the control enclosure is vulnerable to static electrical
charges. Avoid contact with the PCB.
• Choose an appropriate power source with correct voltage settings for the
specification of the control.
• Do not use a separate device between control and motor to switch motor
ON or OFF during operation.

Step 4 – Preliminary Setup

DIP

Figure 4 - Inside layout of control.

AC LINE VOLTAGE SELECTOR SWITCH – If the control is to be operated from a

230 VAC power supply, slide the selector switch from “115V” to “230V.”

AC LINE VOLTAGE JUMPER – If the control is to be operated from a two-phase

230 VAC power supply, where both lines are hot (typically in the USA), then
remove the jumper wire between the spades labeled “BYPS1” and “BYPS2.”

DIP SWITCHES FOR MOTOR MATCHING – Figure 4 shows a bank of 8 DIP

switches, factory-set with 4, 5, 6, and 7 ON. Set switches 1-7 to match the
type, voltage, armature speed (not output speed of geared motor), current,
and horsepower ratings on the Bodine motor nameplate per Table 3.
For non‑Bodine motors, or Bodine motors not listed in Table 3, identify the motor
in Table 3 with the closest voltage, armature speed, current, and horsepower
ratings and use those DIP switch settings. Leave switch 8 OFF for 0-90 VDC
output or switch it ON for 0-180 VDC output (with 230 VAC input only).

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 Table 3 – DIP Switch Settings
Typical Input
Bodine Rated Armature Rated Motor DIP Typical Current
Current at Max.
Motor Volts Speed Current Power Switches Range of TORQ.
TORQ Setting
Type (DC) (RPM)1 (Amps)2 (HP) ON Pot. (DC Amps)3
(RMS Amps)4
24A0 130 2500 0.22 1/50 Consult Bodine Support
24A2 130 2500 0.30 1/29 4,5,6,7 0-0.65 1.0
24A4 130 2500 0.48 1/17 3,4,6,7 0-0.8 1.3
24A4 90 2500 0.58 1/20 4 0-.98 1.3
24A4 90 | 130 2500 .56 | .81 1/23 | 1/11 4 0-0.92 1.3
24A46 115 11500 1.1 1/7 3,5 0-1.5 8.2
33A35 90 | 130 2500 .78 | 1.0 1/16 | 1/8 3,5 0-2.4 2.6
33A3 130 2500 0.74 1/12 4 0-0.92 1.3
33A3 130 2000 0.71 1/12 3 0-1.36 1.6
33A55 130 2500 0.91 1/8 2,7 0-2.4 2.7
33A5 90 2500 1.6 1/7 2,4,5 0-3.0 3.8
33A55 90 |130 2500 1.4| 1.8 1/8 | 1/4 3,4,5 0-2.2 2.5
33A55 90 |130 2500 1.3 | 1.7 1/8 | 1/4 3,4,5 0-2.2 2.5
33A5 130 2000 1.4 1/6 3 0-1.38 1.8
33A75 90 | 130 2500 1.8 | 2.4 1/6 | 1/3 2,4,5 0-3.0 3.8
42A35 130 2500 1.0 1/8 2,5,7 0-3.0 4.9
42A45 130 2000 1.3 1/6 2,5,7 0-2.7 4.3
42A5 90 2500 2.27 1/4 2,3,4,5 0-4.0 5.4
42A55 90 | 130 2500 1.9 | 1.8 3/16 | 1/4 1,3,4 0-4.3 6.9
42A55 90 | 130 2500 2.1 | 2.8 3/16 | 3/8 1,3,4 0-4.3 6.9
42A55 130 2500 1.8 1/4 2,4,5 0-3.0 3.9
42A55 130 2500 2.7 1/3 2,4,5 0-3.0 4.2
42A75 130 2500 2.3 1/3 2,3,4,5 0-3.8 5.3
42A75 130 2500 3.4 1/2 1,2,3,4,5 0-5.9 7.5
42A75 130 2500 3.3 7/16 2,3,4,5 0-3.8 5.3
24A2 180 1725 0.13 1/19 4,6,7,8 0-0.2 0.30
24A4 180 2500 0.30 1/19 4,6,7,8 0-0.5 0.8
24A4 180 1725 0.18 1/32 4,6,7,8 0-0.3 0.40
33A3 180 1725 0.33 1/23 4,6,7,8 0-0.6 0.80
33A3 180 1725 0.31 1/23 4,6,7,8 0-0.6 0.90
33A5 180 1725 0.41 1/14 3,4,5,6,7,8 0-0.8 1.3
33A5 180 1725 0.62 1/11 3,5,6,7,8 0-1.1 1.5
33A5 180 2500 0.80 1/7 1,2,3,6,8 0-2.1 2.2
33A5 180 3000 0.89 1/6 1,2,3,6,8 0-1.2 1.9
33A75 180 3000 1.3 1/4 2,5,8 0-2.6 3.5
33A7 180 1725 0.88 1/6 3,5,8 0-1.7 2.0
42A5 180 1725 0.85 1/6 3,5,8 0-1.3 2.1
42A5 180 1725 0.85 1/5 3,5,8 0-1.71 2.1
42A5 180 2500 1.2 1/4 2,5,8 0-2.7 8.5
42A55 180 3000 1.17 1/5 2,5,8 0-2.5 4.1
42A5 180 1725 0.85 1/6 3,5,8 0-1.7 2.1
42A7 180 1725 1.0 1/5 2,5,8 0-2.0 3.2
42A75 180 3000 1.5 1/4 2,3,8 0-3.3 6.9
1. Armature speeds are based on 130VDC (or 180VDC). For armature speed of a geared motor, multiply the output speed at the drive-
shaft by the gear ratio. Note that “PWM rated” motors, or motors rated at 130 VDC, will run about 69% slower with an unfiltered
control because of the 90VDC max output voltage.
2. If the user desires to install their own armature fuse on the control output to protect the motor from continuous overloads, base
fuse ratings on the motor current rating in this column. The fuse should be sized at 1.2 times the current rating in this column.
3. Peak current available with TORQ pot in fully CW position. This current may exceed the continuous rating of the motor, in which
case it is intended for intermittent overload conditions only. It is the user’s responsibility to make sure the application does not
exceeds continuous rating of the motor or gearing.
4. Use this column for sizing a line fuse on the control input. The fuse should be sized at 1.2 times the current rating in this column.
5. These motors are capable of exceeding the continuous output rating of the control. The loading on these motors must be limited
to keep their continuous current draw at 2.1A or less.
6. The REG potentiometer must be turned fully CCW (off) for high-speed type 24A4BEPM motor.
7. The load/current of our 42A5 “SCR Rated”, 90V, 2500 rpm gearmotors may not exceed 2.1 amps (max) rating of control.

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AC LINE FUSES – Model 1865 has a 12A fuse already installed in both the “F1”
and “F2” fuse holders. A fuse is only really necessary in “F2” if a two-phase
230 VAC power supply (with two hot sides) is used.

Step 5 – Connect the Motor

A cord should be used for the motor connection in order to properly seal
the liquid tight fitting. The fitting will accept cord diameters between 0.17”
and 0.47” diameter. The length of the cord should be kept short for minimum
voltage drop and only copper wire with 60O C rated insulation should be used.
Loosen the nut from the liquid tight fitting and insert the cord through the
fitting and into the enclosure. Connect the two motor power leads to “A1” and
“A2” on the terminal block inside the control. The terminal
White block
+ will accept
wire sizes from 18 to 14 gauge. The terminal block screws should be tightenedA2
Motor
to 6 lb-in (0.678 Nm). Connect the motor frame ground toBlack
“CHASSIS GROUND”
—
on the terminal block. Refer to the connection diagramsGreen
for Bodine DC A1
motors
or
in Figures 5 and 6. If the motor doesn’t rotate in theGreen-Yellow
desired direction
Traces as
connected, switch the two motor wires. Note that these connection diagrams
apply to Bodine motors only. When the connections are done, tighten the nut

White + Brown +
A2 A2
Motor Motor
Black — Light Blue — A1
A1
Green or
Green-Yellow Traces Green-Yellow Traces

on the liquid tight fitting. Figure 5 – Connection diagram for

Bodine 130V DC motors.
Brown +
A2
Motor Figure 6 – Connection diagram for Bodine 180V DC motors.
Light Blue — A1
Step 6 – Connect AC Line Cord
A cord should be used Traces
Green-Yellow for the AC power connection in order to properly seal
against water through the liquid tight fitting. See Step 5 for cord and wire
specifications. Connect the hot side of the line to “L1” and the neutral side to
“L2.” Connect earth ground to the terminal labeled “CHASSIS GROUND.” The
barrier terminal block screws should be tightened to 6 lb-in (0.678 Nm).

Step 7 – Close and Seal the Enclosure

Close the hinged cover and tighten the four screws, one at each corner.

Step 8 - Connect to AC Power

After all other connections are made and the control is closed, connect the
AC line cord to the AC power supply.

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 Figure 7 – Electrical connections for Model 1865.

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OPERATION
Step 9 – Check System Before Starting
WARNING
• Recheck all connections.
• Do not open the cover of the inverter when the power is ON to avoid injury
caused by electrical shock.
• Do not attempt to wire circuitry while power is on.

CAUTION
• Recheck for proper setting of AC Line Voltage selector switch.
• Do not attempt to make or break connections between motor and control
when the power supply is turned on, or the control may be damaged due
to a surge peak.
• Check that motor is securely mounted.
• Test motor unloaded first to verify proper setup.
• Check all rotating members. Be sure keys, pulleys, etc. are securely
fastened and safety guards are in place.
• Check for proper mounting and alignment of products, and verify safe
loading on shafts and gears.
• The control can be easily operated from a low-speed to a high-speed.
Reconfirm the operating speed range of the motor and the machinery you
are controlling.

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 TYPE UPM
ADJUSTABLE SPEED
TORQUE CONTROL

SPEED•DREHZAHL•VITESSE
50 60
40
30 70

20 80 Speed
10
0 100
90
Adjustment
Dial

Power
Indicator
Lamp
ON•EIN•MARCHE

Power
OFF• AUS• ARRET
Toggle
Switch

FIGURE 8 – Control panel layout

Step 10 – Operate the Control

The Model 1865 control is operated using the switch and speed dial on the
front panel of the control. See Figure 8 for panel layout.
1) Turn the AC power ON using the power toggle switch. The power indicator
lamp will illuminate.
2) Adjust speed by turning the speed adjustment dial. Turning the dial fully
CCW will produce the minimum output speed, as set by the MIN trim pot
inside the control. Turning the pot fully CW will produce the maximum output
speed, as set by DIP switch #8 and the MAX trim pot inside the control.
3) To stop the motor, turn the AC power off using the power toggle switch.
4) If the motor does not start promptly and run smoothly, refer to
the“TROUBLESHOOTING” section.

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Step 11 – Adjust Trim Pots (Optional)
Model 1865 has trim pots which have been factory adjusted for most
applications. Some applications may require readjustment of the trim pots in
order to tailor the control to exact requirements. The control will have to be
opened in order to adjust the trim pots.

WARNING
Do not adjust trim pots with main power on if possible. If adjustments are
made with power on, insulated adjustment tools must be used and safety
glasses must be worn. High voltage exists in this control. Electrocution and/
or fire hazard can result if caution is not exercised.

Figure 9 - Location of trim pots inside enclosure.

MIN: Minimum Speed Limit

The MIN trim pot can be adjusted if it is
desired for the motor to run at a minimum
speed higher than 0 rpm with the main
speed dial set at “0.” The maximum setting 0 VDC 50 VDC
(fully clockwise) produces an output voltage
of about 50 VDC. Note that increasing the MIN.
minimum speed will also increase the
Figure 10 – Factory setting
maximum speed, so the MAX trim pot may
of MIN trim pot.
need to be adjusted.

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MAX: Maximum Speed Limit
The MAX trim pot can be adjusted if it is
100%
desired for the motor to run at a maximum
speed lower than the motor rating with the
main speed dial set at “100.” The minimum
setting (fully counterclockwise) produces 60% >100%
an output voltage of about 60% of the full
output (depends on whether control is set MAX.
up for 90V or 180V maximum output). Figure 11 –
Factory setting of MAX trim pot.
ACC: Acceleration Time
Turn the ACC trim pot to change the 2 SEC (0-90V)
acceleration time. The minimum setting 4 SEC (0-180V)

(fully counterclockwise) produces a

voltage ramp time of approximately 0.2
seconds. The maximum setting (fully 10 SEC. (0-90V)
0.2 SEC. 20 SEC. (0-180V)
clockwise) produces a voltage ramp time ACC.
of approximately 10 seconds for a 0 to 90
VDC output and 20 seconds for a 0 to 180 Figure 12 –
VDC output. Certain loading conditions Factory setting of ACC pot.
may prevent the motor from actually
accelerating as quickly as the output
voltage ramps up.

DEC: Deceleration Time

Turn the DEC trim pot to change the 2 SEC (90-0V)
deceleration time. The minimum setting 4 SEC (0-180V)
(fully counterclockwise) produces a
voltage ramp time of approximately 0.2
seconds. The maximum setting (fully 10 SEC. (90-0V)
clockwise) produces a voltage ramp time 0.2 SEC.
DEC.
20 SEC. (180-0V)
of approximately 10 seconds to ramp the
output voltage down from 90 to 0 VDC and Figure 13 –
20 seconds to ramp down from 180 to 0 VDC. Factory setting of DEC pot.
Certain loading conditions may prevent the
motor from actually decelerating as quickly
as the output voltage ramps down.

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 TORQ: Output Current Limit
The TORQ trim pot can be adjusted to change
the output current limit. Since the current
drawn by a DC motor is directly proportional
180- to the output torque of the motor, limiting the
0% TORQ 250% current available to the DC motor will limit the
load the motor is capable of driving and set
Figure 14 – the stall point. Turn the TORQ trim pot to set
Factory setting of TORQ trim pot. the stall point from 0% (fully counterclockwise)
to roughly 180 – 250% (fully clockwise) of the
motor’s rated torque (assuming DIP switches are properly set). Note that the
factory setting of the TORQ trim pot allows the motor to draw more than its
rated current and will allow the motor to overheat if the overload condition is
allowed to persist continuously. There is no shut-down function in the control
to protect against a continuous overload. The red “LMT” LED will illuminate
when the current limit set by the TORQ trim pot is reached.

REG: IR Compensation for Speed Regulation

1-2% SPEED REGULATION
WITH STOCK BODINE MOTORS
The REG trim pot sets the gain of the IR
compensation. It is factory set so that motor
speed varies no more than about 2% of
rated speed from no load to full load with
0 GAIN FULL GAIN the DIP switches set properly. Increased IR
REG. compensation can be obtained by turning the
Figure 15 – REG trim pot clockwise. However, this may
Factory setting of REG trim pot. cause some systems to become unstable. If
this happens, reduce the compensation by
turning the REG pot counterclockwise.

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TROUBLESHOOTING
WARNING
• Do not open the cover of the control when the power is ON to avoid injury
caused by electrical shock.

This control does not require maintenance under normal conditions. If you
encounter a problem, read all instructions provided with this control and
double check the wiring. If problems persist, contact your source of purchase
or a Bodine Authorized Service Center and describe the problem in detail.
Performing unauthorized repairs will void the Warranty.

GENERAL EVALUATION – Knowing the circumstances under which the

problem occurred can help to identify the root cause of the problem.

Has the system ever operated properly? If the control was just installed and
doesn’t work right, then something probably wasn’t done correctly in the
installation. However, if the system was working for an extended period of
time and just recently stopped working, then the control probably was initially
installed properly, but something has somehow changed.

Is the problem continuous or intermittent? If the problem always occurs

and never goes away, then it would indicate something inherently wrong in
the connections or a defective component. However, if the system operates
properly most of the time and only occasionally does something wrong, then
this might indicate loose connections or electrical noise interference.

Refer to Table 4 on the next page for a description of some of the more
common problems and their causes.

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 Table 4 - General problem evaluation method
PROBLEM
Motor does not run
Motor runs, but in
wrong direction
Motor runs, but speed
can’t be adjusted
Motor runs, but speed
is too high or too low
Motor runs but with
abnormal speed variation
Figure 16 – Location of LED Status Indicators inside the enclosure
18
CHECK POINT
Is main power lamp
illuminated?
Is the red “LMT”
LED illuminated?
Is the main speed
pot damaged?
Is wiring to the
motor correct?
Is the main speed
pot damaged?
Is the red “LMT”
LED damaged?
Is the motor specification
correct?
Is the gear ratio correct?
Is the MAX trim pot
setting correct?
Is DIP switch 8 set for
proper output voltage?
Is the loading variation
too large?
Are DIP switches set
properly to match
the motor?
Is REG trim pot set properly?
IF “YES,” THEN …
• Check that power source
is switched on.
• Reconfirm the power
voltage level.
• Check that TORQ trim
pot is not set too low.
• Check that motor is
not overloaded.
• Examine the speed
pot and correct it.
•S
 witch the two motor wires.
• Examine the speed
pot and correct it.
• Check that TORQ trim
pot is not set too low.
• Check that motor is
not overlooked.
• Reconfirm motor
specification.
• Reconfirm gear ratio.
• Check MAX trim pot settings.
• Set DIP switch 8 properly.
•R
 educe loading variation.
• Set DIP switches properly.
• Adjust REG trim pot.
www.bodine-electric.com
BODINE LIMITED WARRANTY
The Bodine Electric Company warrants all products it manufactures to be free
of defects in workmanship and materials when applied in accordance with
nameplate specifications. Bodine motors and gearmotors purchased with
and used only with appropriately applied Bodine controls are covered by this
warranty for a period of 24 months from the date of purchase or 30 months from
date of manufacture, whichever comes first. Bodine motors and gearmotors
used with non-Bodine controls and Bodine controls used with non-Bodine
motors and gearmotors are covered by a 12 month warranty period. The
Bodine Electric Company will repair, replace, or refund at its option, any of
its products which has been found to be defective and within the warranty
period, provided that the product is shipped freight prepaid, with previous
authorization, to Bodine or to a Bodine Authorized Service Center. Bodine
is not responsible for removal, installation, or any other incidental expenses
incurred in shipping the products to or from Bodine. This warranty is in lieu
of any other expressed or implied warranty – including, but not limited to,
any implied warranties of merchantability and/or fitness for a particular use.
Bodine’s liability under this warranty shall be limited to repair or replacement
of the Bodine product and Bodine shall not be liable, under any circumstances,
for any consequential, incidental or indirect damages or expenses associated
with the warranted products. Proof of purchase of motor or gearmotor and
matching control as a system must be provided with any claim.

Contact our customer support staff to request a CE Declaration of Conformity

for this product. Please send an e-mail to: info@bodine-electric.com.

Control Type:_____________________ Serial No.____________________

Date of Purchase:_______________ Place of Purchase:_______________

www.bodine-electric.com 19
 Bodine offers over 1,300 standard
gearmotors, motors and
system-matched speed controls.

Visit www.bodine-electric.com
for all your motion control needs.

Bodine offers the widest selection of variable-speed

AC, permanent magnet DC and brushless DC fractional
horsepower gearmotors and motors in the industry. For
complete specifications, 3D CAD drawings, or to order
online, visit bodine-electric.com.

201 Northfield Road | Northfield IL 60093 U.S.A. | 773.478.3515

info@bodine-electric.com | www.bodine-electric.com

07401043.D